North American robotics suppliers saw orders rise 36% in the first half of 2005, putting the industry on pace for a record year, according to new statistics released by Robotic Industries Association (Ann Arbor, MI) the industry's trade group.

A total of 10,712 robots valued at $638.9 million were ordered by North American companies through June. When orders from companies outside North America are included, overall sales for North American robot suppliers totaled 11,381 robots valued at $673.1 million in the first half of 2005.

The April through June quarter was the robotics industry's best ever, with 5396 robots valued at $336.3 million ordered by North American manufacturing companies. The first half surge was led by demand for robots that perform applications such as material handling and arc welding. Orders in the automotive and metalworking industries were especially strong.

RIA estimates that more than 150,000 robots are now at work in factories in the United States, placing the US second only to Japan in terms of robot use.

Mazak Corp. will showcase the company's latest advanced technology solutions and its newly expanded National Technology Center (NTC) at its Touch the Future 2006 event in Florence, KY, November 8 - 10.

With 40 separate machine tools and production technologies under power, Mazak will demonstrate how manufacturers from a broad spectrum of industries, including automotive, aerospace, heavy equipment, die/mold, medical, electronics, and general contract machining can increase their production efficiencies.

"Many manufacturing indicators are up across the industry, including machine tool sales, but pressures to reduce costs and speed up deliveries remain continuous," says Mazak president Brian Papke. "Companies aren't simply demanding more capacity, they're demanding the leanest, most flexible means of production to create a competitive advantage," he explains.

Sharing the TTF 2006 spotlight will be Mazak's National Technology Center, featuring the Center for Multi-Tasking and Manufacturing Excellence. The NTC has been expanded to 69,000 ft² (from 33,000 ft²) and includes floor space for applications engineering, a 200-seat theater, and newly-created classroom and seminar space.

"Manufacturers need applications engineering, space for proving out unique production processes, and continuing training opportunities," says Papke. "The expanded National Technology Center and the Center for Multi-Tasking and Manufacturing Excellence will confirm through training, education, and hands-on demonstrations that significant productivity increases are still possible for North American manufacturing."

New machine tools will be introduced and shown along with the company's wide range of multitasking machines. New machine introductions will include:

• Nexus VCN-510C/50 vertical machining center with 50-taper spindle for high-horsepower, high-torque machining applications;



• Nexus QTN 400 and QTN 450 CNC turning centers extending the made-in-Kentucky Nexus line; and



• High-speed UN600V and UN600H ultra-narrow profile machining centers for high-productivity processing of die cast aluminum.

The company, which is committed to advancing its own manufacturing capabilities worldwide, will guide its customers and guests on tours of the Florence manufacturing plant to view the fourteenth expansion there since 1974.

The American Welding Society (AWS) announces the availability of AWS A5.18/A5.18M:2005: Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding. This specification gives the requirements for classification of solid-carbon-steel electrodes and rods, composite stranded-carbon-steel electrodes, and composite metal-cored-carbon steel electrodes for gas-shielded arc welding. Classification is based on chemical composition of the electrode for solid electrodes and rods, chemical composition of weld metal for composite stranded and composite metal cored electrodes, and the gas - welded mechanical properties of the weld metal for each. Additional requirements are included for manufacture, sizes, lengths, and packaging.

A guide is appended to the specification as a source of information concerning the classification system employed, and the intended use of the electrodes and rods. For more information on AWS programs and publications, visit the Society's web site, www.aws.org.

A strategic alliance agreement has been signed by Juran Institute's President and Chief Executive Officer, Joseph A. De Feo, and Ho-Jin Hwang, President of Wexi Inc., a South Korean provider of management services. The Juran Institute works with quality issues.

Watlow Electric Manufacturing Co. (St. Louis, MO), a manufacturer of heaters, controllers, and temperature sensors, was awarded QC-1 certification from the Los Alamos National Laboratory. Watlow is a supplier for the lab's nuclear-related programs.

Janos Technology Inc. (Keene, NH) a supplier of infrared optical components has moved to a new 40,000 ft² (3716 m²) facility. Included in the factory will be a class 1000 clean room.

Gleason Corp. (Rochester, NY), a manufacturer of gear production machinery, has acquired M&M Precision System Corp (West Carrolton, OH). M&M makes metrology systems.

Brooks Automation (Chemsford, MA) a provider of hardware and software automation to the semiconductor industry, has acquired Helix Technology Corp, a developer of vacuum technology.

Spirax Sarco Inc., (Blythewood, SC) a provider of steam system solutions, has purchased the assets of Emco Flow Systems (Longmont, CO).

SKF Spindle Service (Armada, MI) has expanded its service center network to both ballscrew manufacture and repair in the Detroit area. Replacement bearings will also be available.

Godfrey Wing Inc. (Cleveland) has opened a manufacturing center in Dayton, OH. The metal finishing company's new 20,000 ft² (1858 m²) facility features continuous-flow impregnation technology, and a porosity sealing process for cast-metal components. The company will also offer test services and shot peening.

Maxcor, a holding company that concentrates on acquiring and developing medium-size manufacturing enterprises mainly in the mechanical engineering sector, has acquired ThyssenKrupp MetalCutting. This group of companies includes: Cross Hüller, Hüller Hille and Hessapp, Witzig & Frank, Giddings & Lewis, and Fadal. During 2003 - 2004 ThyssenKrupp MetalCutting had 2735 employees and generated sales of around 490 million euros. It serves customers from the automotive, supply, aerospace, medical, energy, mechanical engineering, tool and die, mold making, and job-shop sectors.

The sale of the MetalCutting business unit completes the portfolio optimization of the company's Technologies segment. In the future, Technologies will concentrate on the business units with growth potential--plant technology, marine systems, and mechanical engineering.

Leistritz AG (Allendale, NJ) has purchased the turbine blade and forging business of ThyssenKrupp Technologies AG. The acquisition includes plants in Remscheid, Germany (ThyssenKrupp Turbinenkomponenten GmbH) and in Winston Salem, NC (Advanced Turbine Components, Inc.). These two plants specialize in forging and machining turbine blades and components for the aerospace and power-generation industries.

Makino (Mason, OH) has opened a new 12,300 ft² (1143 m²) tech center in Los Angeles to serve West Coast customers. The facility will support RAM, wire EDM, and high-speed milling functions.

FMB Machinery USA (West Caldwell, NJ) a maker of bar-feeding equipment, announced that the bar-feeding group of Hydromat Inc. will be a North American distributor of its magazine bar feeders and robotics line. Hydromat will maintain a full inventory of FMB bar feeders, parts, and accessories, and provide full-service technical support.

Cimcool Div of Milacron Inc. (Cincinnati) has announced that Bader Mill Supply Corp. (Oshkosh, WI) will be its new distributor in parts of Wisconsin and Michigan.

Epson Robots (Carson, CA) has appointed Burns Controls Co. (Dallas) as an authorized distributor for the states of Arkansas, Louisiana, New Mexico, Oklahoma, and Texas in the US as well as northern and central states and Mexico. Burns Controls has satellite offices in the cities of Austin, El Paso, Houston, and San Antonio.

Eamonn Fingleton is a Tokyo-based economic commentator and author of the book In Praise of Hard Industries. The observations below are based on a presentation he made to the United States-China Commission, and appeared in the latest issue of The American Conservative. Fingleton can be reached at efingleton@hotmail.com.

Many of America's key economic competitors have, says Fingleton, on balance, strongly benefited from China's industrialization. The most notable example is Japan. That country's current-account surplus last year totaled $181 billion, a record for any nation in world history. It was more than 2.5 times China's 2004 current-account surplus.

Another fact: Japan exports more to China than it imports. Its surplus with China in 2004 ran to nearly $14 billion, up 17% from 2003.

Where imports might pose a significant threat to Japanese jobs, the Japanese government works to minimize the damage. Besides influencing the pace of outsourcing, Japanese policymakers ensure the trend does not entail the leakage abroad of the nation's key production technologies. Thus, says Fingleton, individual corporations are not permitted unilaterally to transfer advanced technologies to foreign operations.

Much of the control stems semiautomatically from Japan's distinctive labor regulation. In principle, employers are foresworn from making layoffs. This principle is applied flexibly: exceptions are permitted in the case of struggling small firms as well as corporate dinosaurs in near-terminal financial difficulties. But as a practical matter, layoffs are not an option for any healthy mainstream Japanese corporation.

Whereas American chief executives are much concerned with the opinions of securities analysts, Fingleton says, a typical Japanese chief executive is necessarily focused on long-term production planning. His principal concern is to create new and ever more productive work for his Japanese colleagues at every level, not least the newest recruits who can be expected to be on the payroll 30 years hence. To this end, he will make sure that, among other things, the corporation spends heavily on research and development.

All this means that a Japanese chief executive's attitude to outsourcing will almost automatically be closely aligned with the Japanese national interest. Because he cannot easily shed labor at home, he will move production activities abroad only after he has lined up new and better work--either more capital intensive or more know-how intensive or both--for his domestic workers.

A Japanese television manufacturer might move assembly operations to China only after redeploying its domestic assembly workers to make liquid crystal displays. This latter activity can be at least 10 X as capital intensive as assembling television sets.

While Japan is the most spectacular example of a nation that has leveraged Chinese industrialization to the advantage of its export industries, it is hardly alone. This should be obvious from the fact that China's surplus with the United States exceeds its surplus with the world as a whole. In other words, while China is a huge net exporter to the United States, it is actually a major net importer from the rest of the world.

A National Research Council study finds we need access to research and development in materials science and engineering (MSE) conducted abroad for our nation's security and economic well-being. There has been a narrowing, or total loss of the technological lead of the United States in some materials fields.

Reasons behind this shift are partially due to two factors:

• Foreign competitors such as China, Korea, India, Japan, and the European Union are making substantial investments in major R&D programs and in science and engineering education.



• US companies are shifting a portion of their MSE R&D overseas as product development and technical support follow manufacturing.

Reinforcing this last tendency is growing availability of intellectual resources offshore, often at less cost. At the same time, there is an increasing availability abroad of unique technologies not found in the US.

The answer, according to the NRC is that the US government and private sector must exploit foreign or joint R&D to benefit domestic innovation.

Global automotive technology provider Ricardo plc (Van Buren Twp., MI) underscored its commitment to the Chinese automotive market with the official opening of its new suite of offices in Shanghai. Located in the Maxdo Centre in the Hongqaio area west of the city.

The new Ricardo facility in Shanghai provides a tangible presence in the rapidly expanding Chinese automotive industry. The company's business activities in China have grown substantially in recent years. Ricardo has traditionally supported the Western joint venture organizations. Most recently, Ricardo has also been assisting the domestic Chinese automakers in the development both of their own product ranges and in training and technology transfer to enable the development of their own research and development capabilities.

Carl Zeiss Industrial Measuring Technology announced it has been honored with the Bosch Group's Supplier Award for the second time. Bosch presented its 2005 Supplier Award to the German-based manufacturer of industrial metrology equipment for its outstanding performance in quality, costs, and delivery reliability during 2003 and 2004. The award also recognizes the company's dedication to continuous development and its technology potential.

The Association for Manufacturing Excellence (AME) has chosen Webster Plastics (Fairport, NY) as the winner of the first AME Manufacturing Excellence Award. The award is given annually to an AME-affiliated company worldwide that shows the most progress in increasing efficiency, customer service and continuous improvement across its enterprise. Webster, a business unit of Parker Hannifin, was chosen for its leadership's dedication to creating a culture of change within the company and their continual pursuit of manufacturing excellence.

New "rebuild/refurbish" program is now available from Almco Inc. (Albert Lea, MN). This work substantially extends the life of any piece of part-feeding equipment whether a round-bowl, a through-feed, or an end-discharge unit, at a cost less than the purchase price of a new model. Almco is also a developer and manufacturer of metal-parts washing-and-drying equipment, and cyclonic filtration systems.

Rising fuel process are chief reason a recent survey of senior executives of large multinational manufacturing companies showed a significant downturn in optimism. The survey, conducted by PricewaterhouseCoopers' Manufacturing Barometer found 46% of respondents, compared to 70% last quarter, are optimistic about the world economy and only 54%, compared to 71% last quarter, are optimistic about the US economy. Higher oil prices continue to impact manufacturers' 12-month forecast. The reduced economic optimism of senior executives is reflected in lower revenue growth estimates and hiring rates.

Most of the manufacturers said oil and energy prices have a strong or moderate negative effect on the US economy, consumer confidence, and profit margins. There was also a significant drop in the number of manufacturers who expect to make major new capital investments over the next 12 months. Only 43% of manufacturers are planning to increase their workforce over the next year--down 9% from last quarter.

Online Development Inc. (Knoxville, TN) a developer of automation hardware and software for OEMs such as Rockwell Automation and ProSoft Technology and developer of the xCoupler enterprise transaction module, announces that it has been selected for participation in the Rockwell Automation Encompass Partner Program.

Software

Manufacturing Engineering: What can immersive visualization or virtual reality systems do for today's manufacturers?

Chris Clover: Immersive visualization enables intuitive and interactive viewing of life-size 3-D computer-generated models. These virtual prototypes enable manufacturing teams to see planned products so production-line planning can begin earlier and better decisions can be made. Manufacturing teams can also give early input on designs that may benefit the build. Manufacturing process simulation allows walking through virtual plant floors, in real-time, ensuring optimal space utilization and production flow. Virtual worlds can even be populated with moving workers and equipment to ensure there is no potential for collision or bottlenecks. Staff input on the production process can be beneficial. Prior to assembly, virtual models can be reviewed with assembly staff, before any work begins. Workers can also practice by building a virtual model first. Developing task memory through simulation can shorten training times, increase safety, and reduce potential damage to real components. Augmented reality allows viewing the virtual world superimposed on real-world environments. For example, someone involved in precision cutting could see a cut line superimposed on a real part. Wiring or interconnected parts could be quality-checked for position and orientation using virtual models as guides.

ME: Can you define what characterizes these systems and how they differ from desktop visualization?

Clover: Typically, virtual reality displays involve 1:1 or larger-scale images on projected, stereoscopic displays with interaction capabilities beyond the mouse and keyboard. For stereoscopic viewing, special electronic or polarized-light glasses separate left and right-eye viewpoints to produce depth perception for life-like images. This is especially beneficial when components in a model are spatially complex, such as engine components. Full-size or larger viewing provides better insight for detection of interferences and other design and process flaws. For intuitive interaction, motion-tracking systems can allow you to walk into or look around virtual models as if they were in front of you. Six degrees of freedom virtual wands allow faster, more natural movement in 3-D space. Virtual gloves allow reaching in and assembling virtual models, and even the ability to feel the model's contours and textures.

ME: How has immersive visualization changed manufacturing for manufacturers in the automotive and aerospace industries?

Clover: Competitive issues drive the need for efficiencies and rapid response to consumer demand. Many of the world's leading manufacturers have incorporated visualization into their design, manufacturing, and other processes for efficiencies throughout the workflow. Vehicles that once took five years to design and build are now being introduced to the marketplace in three years or less. Virtual, immersive models can be modified throughout the design process to create multiple iterations for faster review. Proposed production-line changes can be reviewed in VR to study the effects, without building actual models or disrupting existing production. This eliminates costly and time-consuming trial and error. What-if production scenarios can also be more easily explored. This enables design changes required for manufacturability to be integrated much earlier in the process.

Virtual, immersive models can be modified throughout the design process to create multiple iterations for faster review.

ME: When manufacturers integrate immersive visualization into the design process, can they continue to use the same software they always have?

Clover: The majority of applications will not operate natively in immersive environments and require porting to VR viewing packages. To overcome this, we have partnered with multiple CAD/CAM software vendors, and we've introduced a new middleware package, called Conduit. This software enables almost any graphics-based application to work natively in an immersive display by making non-stereoscopic applications generate stereoscopic views, and enabling motion-tracking and interactive features, even for walk-in VR rooms. The ability to move data directly from the desktop to an immersive environment eliminates time-consuming data preparation, porting, and translation into VR viewers. Further, the enterprise can be unified since applications previously only Unix-compatible can now be driven by commodity PC clusters, driving down the cost of computing and allowing for simple processor and graphics card upgrades in the future. Graphics middleware allows viewing desktop data in virtual environments as easy as selecting a networked printer.

ME: What kind of networked systems are possible with immersive VR today?

Clover: Between offices, users can upload models from a shared network, display it in their visualization center and connect via phone to discuss the data. However, both viewers may not see the model exactly the same way at the same time. For real-time connectivity, rooms in the same building or campus can be connected by optical fiber. Remote users can also access a main computer. However, these point-to-point connections are limited to approximately three kilometers, and may only connect monoscopic images, audio, keyboard, and mouse. Beyond three kilometers, video over IP [Internet Protocol] can be used. Graphics card systems do frame grabbing and send data out at relatively low refresh rates. Some systems will allow global sharing of monoscopic models at real-time frame rates over dedicated networks, but are limited in interaction capabilities. The most powerful transport systems offer compression technology that allow real-time sharing of stereoscopic images with immersive, interactive capabilities over dedicated networks or stereoscopic images over Ethernet or IP networks. Because IP and Ethernet are used, point to multipoint connections are possible, allowing several offices to connect and collaborate. This can benefit intra-company and also key vendor collaboration.

ME: Are immersive VR systems becoming more affordable?

Clover: Absolutely, due to several factors. Probably the biggest cost factor in the past has been the infrastructure costs associated with data conversion between CAD/CAM and VR viewing packages. New middleware, such as Conduit, enables work with native data software, saving time and money. The lower cost of computing power also is enabling new applications for 3-D viewing, providing certain economies of scale. Core VR technology prices, such as the price of stereoscopic projectors, have decreased, but not to the scale of computers. However, features have increased, such as edge blending of multiple projectors for seamless large screens, and those features may be the deciding factor for the end user. Finally, applications are more feature-rich, which can speed a user's data interrogation and reviews. When assessing affordability, the complete return on investment must be considered. As mentioned previously, fewer physical prototypes, minimized changes, faster and better decisions, as well as networked offices which reduce travel costs, all factor in. Just about every company calculates ROI differently, but many areas for cost and time savings are obvious, and are usually significant.

ME: What are some technologies that can extend visualization further into manufacturing?

Clover: Scanning technology is developing to the point where 3-D point clouds of an existing assembly line or production part can be quickly captured. Rapid 3-D modeling of production lines allows easier, faster change scenarios. Captured 3-D models could be used in quality control reports and updates. Or if a production issue arises, the VR model could be viewed by a team to speed problem resolution. Autostereoscopic display technology is developing quickly and could make VR more ubiquitous on plant floors. Currently, seeing high-quality VR images requires special glasses that may not be acceptable on a manufacturing line. Autostereoscopic technology is glasses-free and eliminates any restrictions. Motion tracking and interaction for small areas are also developing quickly and reducing in cost, so VR workstations will be possible.

CAD/CAM software supplier Autodesk Inc. (San Rafael, CA) has acquired Solid Dynamics S.A. (Roanne, France), a developer of mechanical motion analysis software solutions.

With the acquisition, Autodesk will incorporate Solid Dynamics' kinematics/dynamics technology that is used by designers to simulate, analyze, test, and optimize physical motion and loading in mechanical assemblies. Terms of the acquisition were not announced.

Autodesk currently offers Solid Dynamics' technology to its customers as a certified application of its Inventor 3-D design software. The acquisition will allow Autodesk to integrate the technology into future releases of its design software product line.

Gibbs and Associates (Moorpark, CA), developer of GibbsCAM software for programming CNC machine tools, and Mazak-USA (Florence, Kentucky) announced that the companies have signed a strategic collaborative partnership agreement to optimize support for Mazak's multitasking CNC machine tools.

Under the agreement, the companies have entered into a nondisclosure agreement which will allow them to exchange information about and collaborate on next-generation solutions. Working with Mazak, GibbsCAM plans to provide NC programming solutions to support various Mazak machine tools' capabilities and configurations.

CAM software supplier Delcam plc (Birmingham, England) at EMO announced a new German version of FeatureCAM software.

Delcam, which recently acquired FeatureCAM (Salt Lake City), also said the German-language version will be the first of a number of new translations of the software to be released in the second half of the year. FeatureCAM has been available in Japanese and Italian for a number of years. FeatureCAM's feature-based technology shortens programming time and makes CAD/CAM easier to learn by defining parts the same way that machinists describe them.